Nuvera N1800V36 N1821V36 N1800V48 N1824V48 Fuel Cell System Service Manual PDF

Description

Nuvera N1800V36 N1821V36 N1800V48 N1824V48 Fuel Cell System Service Manual – PDF DOWNLOAD

FILE DETAILS:

Nuvera N1800V36 N1821V36 N1800V48 N1824V48 Fuel Cell System Service Manual – PDF DOWNLOAD

Language : English
Pages : 180
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Nuvera N1800V36 N1821V36 N1800V48 N1824V48 Fuel Cell System Service Manual – PDF DOWNLOAD

List of Figures 14
List of Tables 19
General Information 21
Safety information 21
Personal Protective Equipment (PPE) 21
General hazards, warnings, and cautionary statements 22
Hydrogen-specific concerns 23
Hydrogen fueling concerns 24
Swagelok® fitting procedures 25
Swagelok® procedures 25
Scope 25
Safety and warnings 25
Tools required 25
Initial assembly 25
Gauging 26
Reassembly 26
Preparing for service and maintenance 27
Removing and installing the cover panels 27
Scope 27
Safety and warnings 27
Parts and tools required 27
Remove 27
Install 29
Disconnecting the batteries 31
Scope 31
Safety and warnings 31
Parts and tools required 31
Main battery disconnect 31
Main battery connect 32
Low voltage (5 amp) battery disconnect 32
Low voltage (5 amp) battery connect 34
Updating the software 35
Scope 35
Safety and warnings 35
Tools required 35
Update software 35
Installing the Winflash software 40
Scope 40
Safety and warnings 40
Install Winflash software 40
Open and close the tank valve 46
Scope 46
Safety and warnings 46
Parts and tools required 46
Close the tank valve 46
Open the tank valve 46
Service procedures 47
Replacing the air filter 47
Scope 47
Safety and warnings 47
Parts and tools required 47
Prepare 47
Remove 47
Install 47
Replacing the DI filter 48
Scope 48
Safety and warnings 48
Parts and tools required 48
Prepare 48
Remove 48
Install 50
Drain and fill coolant 51
Scope 51
Safety and warnings 51
Parts and tools required 51
Prepare 51
Drain 51
Fill coolant 53
Replacing the main battery 54
Scope 54
Safety and warnings 54
Parts and tools required 54
Prepare 55
Remove 55
Remove 56
Install 57
Install 57
Replacing the 12V batteries 58
Scope 58
Safety and warnings 58
Parts and materials required 58
Prepare 58
Remove 58
Install 59
Storing the Lithium-ion batteries 59
Replacing the DC/DC assembly 62
Scope 62
Safety and warnings 62
Parts and tools required 62
Prepare 62
Remove 62
Install 65
Replacing the main PCB and system controller (STW) 66
Scope 66
Safety and warnings 66
Parts and tools required 66
Prepare 66
Remove 66
Install 68
Replacing the data port 69
Scope 69
Safety and warnings 69
Parts and tools required 69
Prepare 69
Remove 69
Install 70
Replacing the start button 71
Scope 71
Safety and warnings 71
Parts and tools required 71
Prepare 71
Remove 71
Install 72
Replacing the emergency stop button 73
Scope 73
Safety and warnings 73
Parts and tools required 73
Prepare 73
Remove 73
Install 73
Replacing the E-Stop contact block 75
Scope 75
Safety and warnings 75
Parts and tools required 75
Prepare 75
Remove 75
Install 76
Replacing the power cables 77
Scope 77
Safety and warnings 77
Parts and tools required 77
Prepare 77
Remove 77
Install 78
Replacing the hydrogen leak sensors 79
Scope 79
Safety and warnings 79
Parts and tools required 79
Prepare 79
Remove AS5 sensor 79
Remove AS6 sensor 80
Install AS6 sensor 80
Install AS5 sensor 80
Replacing the air compressor 82
Scope 82
Safety and warnings 82
Parts and tools required 82
Prepare 82
Remove 82
Install 83
Replacing the air compressor motor controller 85
Scope 85
Safety and warnings 85
Parts and tools required 85
Prepare 85
Remove 85
Install 86
Replacing the coolant pump 88
Scope 88
Safety and warnings 88
Parts and tools required 88
Parts and tools required 88
Prepare 88
Remove 89
Install 89
Replacing the coolant filter/manifold 90
Scope 90
Safety and warnings 90
Parts and tools required 90
Prepare 90
Remove 90
Remove the particulate filter 91
Install the particulate filter 92
Install 92
Replacing the radiator 94
Scope 94
Safety and warnings 94
Parts and tools required 94
Prepare 94
Remove 94
Clean 95
Install 96
Replacing the fuel cell stack 97
Scope 97
Safety and warnings 97
Parts and tools required 97
Prepare 97
Remove 97
Install 100
Replacing the truck contactor 102
Scope 102
Safety and warnings 102
Parts and tools required 102
Prepare 102
Remove 102
Install 103
Replacing the battery contactor 104
Scope 104
Safety and warnings 104
Parts and tools required 104
Prepare 104
Remove 104
Install 105
Replacing the DC/DC contactor 106
Scope 106
Safety and warnings 106
Parts and tools required 106
Prepare 106
Remove 106
Install 107
Replacing the current transducer 108
Scope 108
Safety and warnings 108
Parts and tools required 108
Prepare 108
Remove 108
Install 109
Replacing the fuses 111
Scope 111
Safety and warnings 111
Prepare 111
Remove/Install 111
Replacing the humidifier 114
Scope 114
Safety and warnings 114
Parts and tools required 114
Prepare 114
Remove 114
Install 116
Replacing the hydrogen fill line 117
Scope 117
Safety and warnings 117
Parts and tools required 117
Prepare 117
Remove 117
Install 119
Replacing the hydrogen fill port 121
Scope 121
Safety and warnings 121
Parts and tools required 121
Prepare 121
Remove 121
Install 122
Replacing the hydrogen regulator 123
Scope 123
Safety and warnings 123
Parts and tools required 123
Prepare 123
Remove 124
Install 125
Replacing the hydrogen recirculation pump 126
Scope 126
Safety and warnings 126
Parts and tools required 126
Prepare 126
Remove 126
Install 127
Replacing the hydrogen fuel tank 129
Scope 129
Safety and warnings 129
Parts and tools required 129
Prepare 129
Remove 130
Install 131
Replacing the hydrogen purge valve 132
Scope 132
Safety and warnings 132
Parts and tools required 132
Parts and tools required 132
Prepare 133
Remove 133
Install 133
Replacing the hydrogen pressure sensors 135
Scope 135
Safety and warnings 135
Parts and tools required 135
Prepare 135
Remove 135
Install 136
Replacing the coolant temperature and pressure sensors 137
Scope 137
Safety and warnings 137
Parts and tools required 137
Prepare 137
Remove 137
Install 139
Replacing the cathode Mass Air Flow (MAF) sensor 140
Scope 140
Safety and warnings 140
Parts and tools required 140
Prepare 140
Remove 140
Install 141
Replacing the cathode temperature and pressure (TMAP) sensors 142
Scope 142
Safety and warnings 142
Parts and tools required 142
Prepare 142
Remove 142
Install 144
Replacing the dewatering connector 145
Scope 145
Safety and warnings 145
Parts and tools required 145
Prepare 145
Remove 145
Install 146
Replacing the antenna 147
Scope 147
Safety and warnings 147
Parts and tools required 147
Remove 147
Install 148
Replacing the water reservoir 149
Scope 149
Safety and warnings 149
Parts and materials required 149
Prepare 149
Remove 149
Install 151
Remove 152
Install 154
Replacing the main electrical box 156
Scope 156
Safety and warnings 156
Parts and materials required 156
Prepare 156
Remove 156
Install 157
Replacing the 24V DCDC 158
Scope 158
Safety and warnings 158
Parts and materials required 158
Prepare 158
Remove 158
Install 159
Replacing the pre-charge resistor 160
Scope 160
Safety and warnings 160
Parts and tools required 160
Prepare 160
Remove 160
Install 161
Storage procedures 162
Storage 162
Short-term storage 162
Mid-term storage 162
Long-term storage 163
Commissioning the Nuvera® fuel cell system after storage 164
Periodic maintenance procedures 165
Periodic maintenance procedure schedule 165
Clean and inspect radiator 166
Scope 166
Safety and warnings 166
Inspect and clean 166
Coolant maintenance and filtration 167
Safety and warnings 167
Inspect and clean 167
Visual coolant check 170
Scope 170
Safety and warnings 170
Parts and tools required 170
Procedure 170
Procedure 171
Coolant conductivity check 172
Scope 172
Safety and warnings 172
Parts and tools required 172
Prepare 172
Procedure 172
H2 pressure relief 174
Scope 174
Safety and warnings 174
Prepare 174
Procedure 174
Inspect the emergency stop button 176
Scope 176
Safety and warnings 176
Prepare 176
Inspect 176
Special Tools 177
Special tools 177

S.V 05/24